Apparatus and Method for Making OLED Lighting Device

An apparatus for depositing one or more organic material layers of an OLED lighting device upon a first region of a substrate and one or more conducting layers of the OLED lighting device upon a second region, wherein the one or more conducting layers partially or completely cover the one or more organic layers and further extend beyond one side of the organic layers, comprising:

• a) a reusable mask, having one or more open areas, positioned and held in contact with but not bonded to the substrate, wherein one edge of at least one mask open area is structured to have an overhang feature;
• b) one or more sources of a plume of vaporized organic material, wherein the one or more sources provide vaporized organic material having a selected intrinsic plume shape with an intrinsic cutoff angle, such that the intrinsic cutoff angle defines a region about the vapor plume centerline that includes 90% of the total flux of vapor, and the one or more organic materials are selected to form one or more layers of the OLED lighting device upon the substrate, and the vaporized organic material plume is shaped, on the side of the plume corresponding to the overhang feature of the mask open area, so as to limit substantial transfer of organic material on said side to angles less than or equal to a selected cutoff angle to the first region of the substrate, wherein said angle is relative to normal to the substrate surface;
• and
• c) one or more sources of a plume of vaporized conducting material that transfer conducting material to the second region of the substrate, wherein the one or more sources provide vaporized conducting material having substantially the same intrinsic plume shape with substantially the same intrinsic cutoff angle as that of the vaporized organic material and the second region partially or completely overlaps the first region and further extends beyond the first region on the side of the first region corresponding to the overhang feature of the mask.